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20

Sliding Rotator Wreckers – Operation and Maintenance

Models: CSR50 - CSR65 - CSR85

REV. 0

SEPTEMBER 19, 2022

1.1.1

Chassis

The chassis supports all the wrecker components, which are shown in Figure 1.

FIGURE 1 — CHASSIS AND WRECKER COMPONENTS (EXAMPLE)

Summary of Contents for CSR50

Page 1: ...Model s CSR50 CSR65 CSR85 September 19 2022 Document number 8923303 Revision 0 Original Instructions SLIDING ROTATOR WRECKERS OPERATION AND MAINTENANCE NRC INDUSTRIES COM Serial number ...

Page 2: ...Operation and Maintenance 2 Models CSR50 CSR65 CSR85 REV 0 SEPTEMBER 19 2022 Sliding Rotator Wreckers Operation and Maintenance ...

Page 3: ...in at any time without notice Please send your comments and questions to NRC Industries Inc 2430 Principale St Saint Paul d Abbotsford QC J0E 1A0 CANADA Tel 450 379 5796 Fax 450 379 5995 For any questions about the winches you can contact the manufacturers directly DP Winch TWG Inc PO Box 1130 Jenks OK 74037 1130 Tel 918 298 8300 Fax 918 298 8301 Website www dovertwg com Ramsey Winch Company PO Bo...

Page 4: ...Operation and Maintenance 4 Sliding Rotator Wreckers Operation and Maintenance Models CSR50 CSR65 CSR85 REV 0 SEPTEMBER 19 2022 ...

Page 5: ...Operation and Maintenance REVISION HISTORY Revision Date Description 0 2022 09 07 Initial release 5 Sliding Rotator Wreckers Operation and Maintenance Models CSR50 CSR65 CSR85 REV 0 SEPTEMBER 19 2022 ...

Page 6: ...Operation and Maintenance 6 Sliding Rotator Wreckers Operation and Maintenance Models CSR50 CSR65 CSR85 REV 0 SEPTEMBER 19 2022 ...

Page 7: ...tions for use 59 3 OPERATION 61 3 1 Operating principles 61 3 2 Preparing the wrecker for optimal performance 66 3 3 Safety guidelines 68 3 4 Familiarizing yourself with the equipment 69 3 5 Emergency hydraulic bypass 70 3 6 Common operating procedures 72 3 7 Using the outriggers 74 3 8 Using the underlift 77 3 9 Using the boom 93 3 10 Using the winches 96 3 11 Using the remote control 98 3 12 Usi...

Page 8: ...lure 157 6 3 Pump failure 158 6 4 Truck failure 158 6 5 Underlift stinger failure 158 7 STORAGE 159 8 DISASSEMBLY AND DISPOSAL 161 9 ACCESSORIES 163 9 1 Forks and fork holders 164 9 2 Holders with integrated forks 166 9 3 Tow bar brackets 168 9 4 Heavy duty tire lifts 170 9 5 Medium duty tire lifts 172 9 6 Spreader bar 174 9 7 Snatch block 176 9 8 Drawbar adapter 177 9 9 Wood pads 179 9 10 Stabili...

Page 9: ...MENTS COVERING COMPONENTS NOT MANUFACTURED BY NRC ARE FOUND WITH THE OPERATOR S MANUALS DELIVERED WITH THE EQUIPMENT C WHAT IS NOT WARRANTED PURSUANT TO THE TERMS OF THIS WARRANTY INDUSTRIES NRC IS NOT RESPONSIBLE FOR THE FOLLOWING 1 USED EQUIPMENT UNLESS IT IS SPECIFICALLY COVERED BY SEPARATE WARRANTY DOCUMENTS 2 ANY EQUIPMENT THAT HAS BEEN ALTERED OR MODIFIED IN WAYS NOT APPROVED BY INDUSTRIES N...

Page 10: ...DEALER MAKES NO WARRANTY OF ITS OWN ON ANY ITEM WARRANTED BY INDUSTRIES NRC AND MAKES NO WARRANTY ON OTHER ITEMS UNLESS IT DELIVERS TO THE PURCHASER A SEPARATE WRITTEN WARRANTY DOCUMENT SPECIFICALLY WARRANTING THE ITEM THE SELLING DEALER HAS NO AUTHORITY TO MAKE ANY REPRESENTATION OR PROMISE ON BEHALF OF INDUSTRIES NRC OR TO MODIFY THE TERMS OR LIMITATIONS OF THIS WARRANTY IN ANY WAY H WARRANTY TE...

Page 11: ...tle Position _______________________________________ Purchaser s Signature X _____________________________________ Date __________________________________ Primary Contact Necessary for Warranty Admin Name _________________________________ Phone _________________________________ The following items are to be performed by dealer at the time of vehicle delivery Customer to sign off each item as verif...

Page 12: ...Operation and Maintenance 12 Sliding Rotator Wreckers Operation and Maintenance Models CSR50 CSR65 CSR85 REV 0 SEPTEMBER 19 2022 ...

Page 13: ...t of world 2006 42 CE X 2014 30 UE X 2014 53 UE X 768 2008 CE X Harmonized standards CE Rest of world EN 60204 1 X EN 82079 1 X EN ISO 12100 X EN 14492 1 for the winches X Other standards CE Rest of world SAE J2512 X SAE J706 for the winches X FMVSS CMVSS 108 Canada and USA X 13 Sliding Rotator Wreckers Operation and Maintenance Models CSR50 CSR65 CSR85 REV 0 SEPTEMBER 19 2022 ...

Page 14: ...Operation and Maintenance 14 Sliding Rotator Wreckers Operation and Maintenance Models CSR50 CSR65 CSR85 REV 0 SEPTEMBER 19 2022 ...

Page 15: ...ures l Chapter 6 provides the operating method in case of an accident or equipment breakdown l Chapter 7 provides information about taking the wrecker in and out of storage l Chapter 8 provides information for disassembling and disposing of the wrecker l Chapter 9 contains information about the accessories that can be used with the equipment Document conventions The following conventions are used ...

Page 16: ...ion and Maintenance Models CSR50 CSR65 CSR85 REV 0 SEPTEMBER 19 2022 Applicable models and serial numbers This manual is intended for use with the following models with serial numbers within the following ranges only l CSR50 001 to l CSR65 001 to l CSR85 001 to ...

Page 17: ... not avoided could result in serious injury or death A warning may or may not involve a property damage hazard Indicates a hazardous situation that if not avoided could result in minor or moderate injury A caution may or may not involve a property damage hazard Indicates information that should be read to avoid equipment damage 17 Sliding Rotator Wreckers Operation and Maintenance Models CSR50 CSR...

Page 18: ...Operation and Maintenance 18 Sliding Rotator Wreckers Operation and Maintenance Models CSR50 CSR65 CSR85 REV 0 SEPTEMBER 19 2022 ...

Page 19: ...h the same main components Only their sizes and capacities are different See Section 1 2 Technical specifications for the wrecker model specifications Seven underlift models are available and can be installed on any sliding rotator system model l HD 3 Heavy Duty three stage l HDE 3 Heavy Duty Euro three stage l SHD 3 Super Heavy Duty three stage l LSHDE 3 Long Super Heavy Duty Euro three stage l X...

Page 20: ...ding Rotator Wreckers Operation and Maintenance Models CSR50 CSR65 CSR85 REV 0 SEPTEMBER 19 2022 1 1 1 Chassis The chassis supports all the wrecker components which are shown in Figure 1 FIGURE 1 CHASSIS AND WRECKER COMPONENTS EXAMPLE ...

Page 21: ... front left front right rear left and rear right Figure 2 shows the outrigger components NOTE The three stage and two stage outriggers are used the same way FIGURE 2 OUTRIGGERS EXAMPLE 21 Sliding Rotator Wreckers Operation and Maintenance Models CSR50 CSR65 CSR85 REV 0 SEPTEMBER 19 2022 ...

Page 22: ...on and Maintenance 22 Sliding Rotator Wreckers Operation and Maintenance Models CSR50 CSR65 CSR85 REV 0 SEPTEMBER 19 2022 1 1 3 Boom Figure 3 shows a three section boom and its components FIGURE 3 BOOM EXAMPLE ...

Page 23: ... 1 shows the location of each type of winch 1 1 5 Underlift The underlift has a vertical section a horizontal telescopic stinger and a T bar as shown in Figure 4 The horizontal stinger can be extended and retracted to allow the T bar to reach the vehicle to be towed FIGURE 4 UNDERLIFT EXAMPLE 23 Sliding Rotator Wreckers Operation and Maintenance Models CSR50 CSR65 CSR85 REV 0 SEPTEMBER 19 2022 ...

Page 24: ...d power increase Proportional controls allow you to use very slow speeds for greater precision and maximum control of the load Figure 5 shows the electronic control panel on the left hand side and Table 1 explains the pictograms used to identify the various controls and switches These brief descriptions are not operating instructions to learn how to operate the components see the procedures in the...

Page 25: ...Operation and Maintenance FIGURE 5 CONTROL PANEL LEFT HAND SIDE EXAMPLE 25 Sliding Rotator Wreckers Operation and Maintenance Models CSR50 CSR65 CSR85 REV 0 SEPTEMBER 19 2022 ...

Page 26: ...Operation and Maintenance 26 Sliding Rotator Wreckers Operation and Maintenance Models CSR50 CSR65 CSR85 REV 0 SEPTEMBER 19 2022 FIGURE 6 DISPLAY PANEL CLOSED LEFT HAND SIDE EXAMPLE ...

Page 27: ...Operation and Maintenance FIGURE 7 DISPLAY PANEL OPEN LEFT HAND SIDE EXAMPLE 27 Sliding Rotator Wreckers Operation and Maintenance Models CSR50 CSR65 CSR85 REV 0 SEPTEMBER 19 2022 ...

Page 28: ...utrigger when the direction switch is set to vertical Retracts the right outrigger when the direction switch is set to horizontal Raises the right outrigger when the direction switch is set to vertical Extends the right outrigger when the direction switch is set to horizontal Lowers the right outrigger when the direction switch is set to vertical Boom to operate the boom see Section 3 9 Rotates th...

Page 29: ...the winches see Section 3 10 Unwinds the winch cables Winds the winch cables Underlift to operate the underlift see Section 3 8 Extends the underlift Retracts the underlift Unfolds the underlift stinger Folds the underlift stinger 29 Sliding Rotator Wreckers Operation and Maintenance Models CSR50 CSR65 CSR85 REV 0 SEPTEMBER 19 2022 ...

Page 30: ...nctions that are available on the main control panels of the wrecker Figure 8 shows a remote control and Table 2 explains the pictograms that are unique to the remote control Table 1 explains the remaining pictograms which are also used on the control panels These brief descriptions are not operating instructions to learn how to operate the components see the procedures in the relevant sections of...

Page 31: ... the boom rotation and slider and control of the underlift For more information see Section 1 1 6 Control panels 1 1 8 Hydraulic and pneumatic system The CSR50 CSR65 and CSR85 models feature an electro hydraulic system that supplies and distributes hydraulic power to the boom underlift etc 1 1 9 Electrical system The CSR50 CSR65 and CSR85 models feature an electrical system that supplies the elect...

Page 32: ...45 kN 50 tons 578 kN 65 tons 756 kN 85 tons Test lifting capacity 445 kN 50 tons 578 kN 65 tons 756 kN 85 tons Boom capacity fully retracted 445 kN 100 000 lb 578 kN 130 000 lb 756 kN 170 000 lb Boom capacity fully extended 2nd section 178 kN 40 000 lb 338 kN 76 000 lb 448 kN 100 700 lb Boom capacity fully extended 3rd section 89 kN 20 000 lb 209 kN 47 000 lb 260 kN 58 500 lb Effective reach with ...

Page 33: ...y 65 boom elevation Capacity 70 boom elevation 1 2 2 Chassis TABLE 4 CHASSIS SPECIFICATIONS IN METRIC IMPERIAL Element CSR50 CSR65 CSR85 Front axle minimum 8 tonnes 18 000 lb 9 tonnes 20 000 lb 18 tonnes 40 000 lb Rear axle minimum 21 tonnes 46 000 lb 29 tonnes 64 000 lb 30 tonnes 66 000 lb Chassis resisting bending moment RBM minimum 508 kN m 4 500 000 lb in 655 kN m 5 800 000 lb in 655 kN m 5 80...

Page 34: ...s Operation and Maintenance Models CSR50 CSR65 CSR85 REV 0 SEPTEMBER 19 2022 1 2 3 Dimensions Figure 9 to Figure 13 and Table 5 to Table 8 present the dimensions of the wrecker models and their components FIGURE 9 CHASSIS DIMENSIONS SIDE VIEW CSR85 SHOWN ...

Page 35: ... mm 186 6 248 mm 246 7 188 mm 283 WOA 2 590 mm 102 2 590 mm 102 2 590 mm 102 LOA 6 325 mm 249 7 518 mm 296 7 087 mm 279 OH 1 397 mm 55 1 397 mm 55 1 473 mm 58 TB 711 1 830 mm 28 72 1 016 1 830 mm 40 72 1 422 1 830 mm 56 72 H 3 150 mm 124 3 277 mm 129 3 454 mm 136 For a 43 in truck frame height 35 Sliding Rotator Wreckers Operation and Maintenance Models CSR50 CSR65 CSR85 REV 0 SEPTEMBER 19 2022 ...

Page 36: ...M AND OUTRIGGER DIMENSIONS SIDE VIEW EXAMPLE TABLE 6 BOOM AND OUTRIGGER DIMENSIONS SIDE VIEW IN METRIC IMPERIAL Dimension CSR50 3 STAGE CSR65 3 STAGE CSR85 A 11 38 m 37 4 13 66 m 44 10 16 84 m 55 3 B 7 42 m 24 4 9 32 m 30 7 11 86 m 38 11 D 2 90 m 9 6 3 15 m 10 4 3 40 m 11 2 X 5 28 m 17 4 5 28 m 17 4 5 99 m 19 8 Z 1 41 m 55 1 41 m 55 1 42 m 56 ...

Page 37: ...EW IN METRIC IMPERIAL Dimension CSR50 3 STAGE CSR65 3 STAGE CSR85 3 STAGE A 11 38 m 37 4 13 66 m 44 10 16 84 m 55 3 C 7 72 m 25 4 9 60 m 31 6 12 57 m 41 3 E 2 62 m 8 7 2 29 m 7 6 2 26 m 7 5 Y 5 39 m 17 8 6 63 m 21 9 7 11 m 23 4 37 Sliding Rotator Wreckers Operation and Maintenance Models CSR50 CSR65 CSR85 REV 0 SEPTEMBER 19 2022 ...

Page 38: ... CSR50 CSR65 CSR85 REV 0 SEPTEMBER 19 2022 FIGURE 13 WORKING AREA DIMENSIONS TOP VIEW EXAMPLE TABLE 8 WORKING AREA DIMENSIONS TOP VIEW IN METRIC IMPERIAL Dimension CSR50 3 STAGE CSR65 3 STAGE CSR85 3 STAGE W1 14 63 m 48 21 67 m 71 1 31 24 m 102 6 W2 16 97 m 55 8 20 82 m 68 4 27 73 m 91 0 ...

Page 39: ...ump Dual piston pump Single pump with load sensing Working hydraulic pressure 207 bar 3 000 psi 241 3 bar 3 500 psi 260 bar 3 770 psi Slide cylinder stroke 2 794 mm 110 3 225 mm 127 3 530 mm 139 Boom lift cylinder Dual Ø 165 mm 6 Dual Ø 165 mm 6 Dual Ø 203 mm 8 39 Sliding Rotator Wreckers Operation and Maintenance Models CSR50 CSR65 CSR85 REV 0 SEPTEMBER 19 2022 ...

Page 40: ...nufacturer for the wire rope specifications As recommended in SAE J959 the strength factor for live or running ropes that wind on drums or pass over sheaves shall be not less than 3 55 As recommended in EN 14492 1 ref 5 15 6 the working coefficient for the first rope layer shall be at least 2 The winch performance in high speed yields line speeds 2x those charted below and yields line pulls 1 2x t...

Page 41: ...5 000 9 071 20 000 11 339 25 000 22 679 50 000 Type 2 speed planetary Planetary Wire rope Lenght m ft 61 200 91 300 Diameter mm in 19 3 4 22 7 8 14 9 16 16 5 8 19 3 4 Winches available for each wrecker model CSR50 S O O O CSR65 S O O CSR85 S O O S standard O optional not available 41 Sliding Rotator Wreckers Operation and Maintenance Models CSR50 CSR65 CSR85 REV 0 SEPTEMBER 19 2022 ...

Page 42: ... mm x 61 m 0 787 x 200 EIPS cable Working load limit 7 512 kg 16 563 lb Breaking load limit 26 308 kg 58 800 lb Wire rope EN 14492 1 2006 Max rope diameter 20 mm Minimum rope breaking strength 355 8 kN 8 000 lb Layer of cable 1 2 3 4 5 Rated line pull per layer Low speed kg lb 18 100 40 000 15 100 33 500 13 000 28 800 11 400 25 300 10 200 22 500 Cable capacity m ft 7 25 16 55 28 95 41 135 56 185 L...

Page 43: ... Wire rope EN 14492 1 2006 Max rope diameter 22 mm Minimum rope breaking strength 445 kN 100 000 lb Layer of cable 1 2 3 4 5 Rated line pull per layer Low speed1 kg lb 18 100 50 000 15 100 41 400 13 000 35 300 11 400 30 700 10 200 27 200 Cable capacity1 m ft 7 25 16 55 28 95 41 135 56 185 Line speed at 17 GPM Low speed1 MPM FPM 4 8 16 5 6 18 7 6 3 21 7 2 24 8 2 27 Note 1 Based on 22 mm 7 8 wire ro...

Page 44: ...Recommended 21 mm x 61 m 7 8 x 200 EIPS 1960 IWRC Working load limit 10 170 kg 22 420 lb Breaking load limit 36 106 kg 79 600 lb Wire rope EN 14492 1 2006 Max rope diameter 23 mm Minimum rope breaking strength 513 2 kN 115 000 lb Layer of cable 1 2 3 4 5 Rated line pull per layer Low speed kg lb 27 215 60 000 23 450 51 700 20 593 45 400 18 370 40 500 16 556 36 500 Cable capacity m ft 10 33 21 71 3...

Page 45: ...ft dimensions and capacity NOTE Underlift specifications are based on the static structural rating FIGURE 14 UNDERLIFT DIMENSIONS EXAMPLE 45 Sliding Rotator Wreckers Operation and Maintenance Models CSR50 CSR65 CSR85 REV 0 SEPTEMBER 19 2022 ...

Page 46: ...38 3 1 775 mm 69 9 1 251 mm 49 2 1 608 mm 63 3 1 988 mm 78 3 1 850 mm 72 8 2 223 mm 87 5 T1 203 mm 8 210 mm 8 3 254 mm 10 235 mm 9 3 235 mm 9 3 281 mm 11 1 281 mm 11 1 T2 153 mm 6 170 mm 6 7 203 mm 8 189 mm 7 4 189 mm 7 4 235 mm 9 3 235 mm 9 3 T3 127 mm 5 133 mm 5 3 152 mm 6 146 mm 5 8 146 mm 5 8 189 mm 7 4 189 mm 7 4 T4 N A N A N A N A N A 146 5 8 146 5 8 T5 195 mm 7 7 135 mm 5 3 195 mm 7 7 135 m...

Page 47: ...3 SSHD 4 LSHD 4 Lifting capacity when retracted 156 kN 35 000 lb 156 kN 35 000 lb 222 kN 50 000 lb 222 kN 50 000 lb 222 kN 50 000 lb 311 kN 70 000 lb 267 kN 60 000 lb 47 Sliding Rotator Wreckers Operation and Maintenance Models CSR50 CSR65 CSR85 REV 0 SEPTEMBER 19 2022 ...

Page 48: ...the CSR50 from the Side l Figure 17 Lifting Capacity of the CSR65 from the Rear l Figure 18 Lifting Capacity of the CSR65 from the Side l Figure 19 Lifting Capacity of the CSR85 from the Rear l Figure 20 Lifting Capacity of the CSR85 from the Side IMPORTANT Note that the capacities in the dotted table cells in this section are based on stability limits and do not exceed 80 of tipping Lifting capac...

Page 49: ...Operation and Maintenance FIGURE 16 LIFTING CAPACITY OF THE CSR50 FROM THE SIDE 49 Sliding Rotator Wreckers Operation and Maintenance Models CSR50 CSR65 CSR85 REV 0 SEPTEMBER 19 2022 ...

Page 50: ...Operation and Maintenance 50 Sliding Rotator Wreckers Operation and Maintenance Models CSR50 CSR65 CSR85 REV 0 SEPTEMBER 19 2022 FIGURE 17 LIFTING CAPACITY OF THE CSR65 FROM THE REAR ...

Page 51: ...Operation and Maintenance FIGURE 18 LIFTING CAPACITY OF THE CSR65 FROM THE SIDE 51 Sliding Rotator Wreckers Operation and Maintenance Models CSR50 CSR65 CSR85 REV 0 SEPTEMBER 19 2022 ...

Page 52: ...Operation and Maintenance 52 Sliding Rotator Wreckers Operation and Maintenance Models CSR50 CSR65 CSR85 REV 0 SEPTEMBER 19 2022 FIGURE 19 LIFTING CAPACITY OF THE CSR85 FROM THE REAR ...

Page 53: ...Operation and Maintenance FIGURE 20 LIFTING CAPACITY OF THE CSR85 FROM THE SIDE 53 Sliding Rotator Wreckers Operation and Maintenance Models CSR50 CSR65 CSR85 REV 0 SEPTEMBER 19 2022 ...

Page 54: ...Operation and Maintenance 54 Sliding Rotator Wreckers Operation and Maintenance Models CSR50 CSR65 CSR85 REV 0 SEPTEMBER 19 2022 ...

Page 55: ... other labels and lifting capacity charts are legible and properly placed Clean and replace them as needed 2 3 Intended use NRC Industries equipment is intended for use only by trained and qualified operators who have carefully read and understood the contents of this manual This product was designed to recover and tow vehicles that do not exceed its lift or tow ratings This manual explains how to...

Page 56: ...nsibilities A full understanding of this manual is essential to safely operate and maintain this equipment Ensure that all operators carefully read and understand this manual before allowing them to operate or maintain the equipment or any of its parts Once operators have read and understood the manual have them sign the Operator record at the end of this manual A PIN code issued by NRC Industries...

Page 57: ... Wear protective clothing Always wear protective gloves Wear a hard hat and safety footwear when walking on the wrecker deck Wear long sleeves bright coloured clothing with reflective strips work gloves and safety boots Wear safety goggles 2 6 2 Follow safety rules Before driving the vehicle check that the power take off PTO is disengaged l The control levers should no longer be functional l The w...

Page 58: ... not in use ensure that the PTO is disengaged Inspect the cables regularly and replace any worn or damaged ones 2 6 3 Avoid danger zones The area underneath the rotating crane mast boom job load is a DANGER ZONE and must never be entered To avoid getting wrapped or tangled keep away from the places where l The winch cables pass though the fairlead at the end of the boom l The winch cables wind ont...

Page 59: ...lines before using the boom and ensure that it does not come into contact with power lines l Keep a safe distance away from the power lines l Do not touch or get out of an energized vehicle l Avoid raising the boom during a thunderstorm since it could attract lightning l Maintain at least 3 m 10 of clearance between all wrecker parts and power lines or devices with more than 50 000 volts See the m...

Page 60: ...equipment When in doubt always assume that the power line or equipment is energized 2 7 2 Hazardous winds Never do any lifting when winds put personnel the public or property at risk Evaluate the size and shape of the load to determine whether the wind could cause problems For example even though the load weight may be within capacity heavy winds and gusts can catch any large surfaces and cause th...

Page 61: ...IPPING OVER WHICH CAN CAUSE PROPERTY DAMAGE INJURIES OR EVEN DEATH The general principles to understand before operating the wrecker are as follows 1 The more you extend the boom the less weight you will be able to lift 2 You can lift more weight from the rear of the wrecker than from the side 3 Lifting from the side of the wrecker works best over the front outriggers 3 1 1 Distributing the wrecke...

Page 62: ...toring the outriggers and that they all stay in contact with the ground at all times Should any of the outriggers start to leave the ground or show an imminent risk of floating immediately stop all lifting or winching operations to avoid any risk of tipping over Any suspended load should be lowered by retracting the boom or winching down DO NOT LOWER THE BOOM as it would move the load away from th...

Page 63: ...les completely off the ground and then lift the front axle just enough to get it off the ground IMPORTANT If you do not put the maximum possible weight on the front outriggers you will not be able to lift the maximum load in this position If all the weight is on the front outriggers and you want to slide and rotate the load the rear outriggers may start to leave the ground when the crane is level ...

Page 64: ...r synthetic cable NOTE See Section 1 2 5 Winches or the manual provided by the winch manufacturer for information about pulling force versus the number of layers of cable remaining on the drum 3 1 6 Increasing winch capacity with pulleys If you need to pull a load that exceeds the safe working limit of the wire or synthetic rope you can reduce line tension and increase pulling capacity using block...

Page 65: ...peration and Maintenance You can calculate the total winch pulley anchor capacity using this formula 65 Sliding Rotator Wreckers Operation and Maintenance Models CSR50 CSR65 CSR85 REV 0 SEPTEMBER 19 2022 ...

Page 66: ...If the load weight is close to the capacity of your wrecker you can move the load and wrecker closer by removing the underlift from the wrecker chassis see Section 3 8 5 Removing the underlift from the wrecker Moving the wrecker closer to the load increases the boom s lifting capacity Lifting a heavy load places significant weight on each outrigger Ensure that the ground is solid enough to prevent...

Page 67: ... hydraulic lift cylinders may come into contact with the top of the underlift stinger when it is lowered and slid to the rear of the chassis To learn how to remove the underlift see Section 3 8 4 Attaching the underlift to the boom Exercise caution when using the wrecker with the underlift since any contact between the boom and underlift can damage the equipment 67 Sliding Rotator Wreckers Operati...

Page 68: ...r After levelling and stabilizing the truck and before operating the underlift boom or winches always ensure that l The auto levelling system is deactivated l The anti twist system is deactivated If the anti twist system wrecker twisted indicator lights up indicating that the wrecker is twisted immediately stop working Examine the vehicle body to find out why it is twisted To correct the issue you...

Page 69: ...ional which means that the further the control levers are moved the more the control speed increases Proportional controls allow you to use very slow speeds for greater precision and maximum control of the load After familiarizing yourself with the equipment we recommend running the engine at low speed 600 850 rpm 69 Sliding Rotator Wreckers Operation and Maintenance Models CSR50 CSR65 CSR85 REV 0...

Page 70: ...tator base for the boom and winches levers The PTO must be engaged in order to use the emergency hydraulic bypass IMPORTANT Never store any tools or other items inside the protective cover The hydraulic levers move when their corresponding electronic levers are activated and any tools or other items inside could restrict the movement of the levers With the emergency hydraulic bypass the boom can b...

Page 71: ...Operation and Maintenance FIGURE 24 EMERGENCY HYDRAULIC BYPASS IN THE SLIDING ROTATOR BASE 71 Sliding Rotator Wreckers Operation and Maintenance Models CSR50 CSR65 CSR85 REV 0 SEPTEMBER 19 2022 ...

Page 72: ...ion An automated transmission or fully automatic transmission might require a different sequence to engage properly Refer to the transmission and PTO operation manuals specific to your vehicle Turn off the wrecker engine and disengage the PTO when the wrecker is not in use The area under the lifting unit is DANGEROUS Stay as far away as possible from the danger zone while the machine is operating ...

Page 73: ...underlift from the boom or remove the underlift from the wrecker body see Section 3 8 5 Removing the underlift from the wrecker 3 6 3 Before leaving the job site After the job is finished store the boom and underlift and prepare the wrecker for safe travel l Attach the underlift to the boom see Section 3 8 4 Attaching the underlift to the boom l Lock the boom in storage position see Section 3 9 4 ...

Page 74: ... and level the wrecker To avoid hitting a person or object make sure you can see the outriggers when extending or lowering them Ensure that ONLY the outrigger feet touch the ground If any other outrigger parts touch the ground the wrecker will be unstable If this occurs move the vehicle to more level ground and try again The general principles to understand before stabilizing the wrecker using the...

Page 75: ...de of the outrigger being moved extend each rear outrigger and lower it just enough so that both rear axle wheels are off the ground 3 7 2 Levelling the wrecker 1 Level the wrecker along the front rear axis using the outrigger control levers and a level 2 Use the touchscreen interface to activate the anti twist system This step is very important as it untwists and significantly reduces the risk of...

Page 76: ...t the outriggers to move vertically 2 Using the levers on the left hand side fully raise all four outriggers simultaneously 3 Remove the locking pins that hold the wood pads on each outrigger Remove the wood pads and put the locking pins back in place Store the wood pads in the toolboxes on each side of the wrecker 4 Use the touchscreen interface to set the outriggers to move horizontally 5 Using ...

Page 77: ...he underlift must be hooked to the boom for transportation The following sections describe all underlift operations Do not drive the wrecker while the underlift is in the storage position resting on the storage pin 77 Sliding Rotator Wreckers Operation and Maintenance Models CSR50 CSR65 CSR85 REV 0 SEPTEMBER 19 2022 ...

Page 78: ...tend the boom to tilt the underlift stinger toward the ground This will position the stinger under the vehicle to be towed l Retract the boom to tilt the underlift stinger away from the ground This will lift the vehicle to be towed l Raise the boom to raise the whole underlift This will raise the vehicle that you are towing l Lower the boom to lower the whole underlift This will lower the vehicle ...

Page 79: ...ft stinger completely using the corresponding lever on the control panel 5 Lower the underlift adjust the angle and extend the stinger using the corresponding controls to position the underlift beneath the vehicle to be towed NOTE The boom is attached to the underlift so they move together 6 Choose a lifting point on the vehicle to be towed It must be both strong enough and have enough clearance f...

Page 80: ...its ancillary equipment fail Failure to do so may lead to serious injury or even death 10 Attach and secure the vehicle to be towed to the towing accessories 11 Lift the vehicle to be towed For clearance and a height that is safe and complies with regulations adjust the underlift stinger to the desired height 12 Fully retract the underlift stinger leaving enough clearance for a 70 degree turn The ...

Page 81: ...ation on recovery and towing procedures for the vehicle to be towed see the owner s manual of the vehicle to be towed The wrecker is now ready to tow the vehicle using the underlift See Section 3 6 3 Before leaving the job site 3 8 3 Unhooking the underlift from the boom 1 Disengage all winches see Section 3 10 2 Disengaging and engaging the winches This will prevent damage to the winch cables 2 S...

Page 82: ...nd Maintenance 82 Sliding Rotator Wreckers Operation and Maintenance Models CSR50 CSR65 CSR85 REV 0 SEPTEMBER 19 2022 FIGURE 26 INSERTING THE UNDERLIFT STORAGE PIN EXAMPLE 3 Slide the storage pin into the pin hole ...

Page 83: ...ted by the storage pin Ensure that the safety attachment is unlocked before lowering the boom This prevents potential damage to the boom and underlift c Lower the boom just enough to allow the boom head hooks to pass under the hinge pin at the top of the underlift d Extend the boom so that the underlift is completely detached and supported by the storage pin 83 Sliding Rotator Wreckers Operation a...

Page 84: ... in front of the wrecker slide it all the way forward so that it is in the slider lock 2 If the boom has been rotated rotate it back into its rotating lock position If the boom has been extended retract it until you can attach the underlift 3 If your wrecker is equipped with the manual safety attachment when the boom head hook is just below the storage pin in the top of the underlift retract the b...

Page 85: ...derlift from the boom see Section 3 8 3 Unhooking the underlift from the boom 2 Disconnect the MultiFaster hydraulic coupler that connects the underlift to the body and place it in the docking bracket on the side of the underlift FIGURE 29 PUT THE HYDRAULIC LINES IN THE DOCKING BRACKET EXAMPLE 85 Sliding Rotator Wreckers Operation and Maintenance Models CSR50 CSR65 CSR85 REV 0 SEPTEMBER 19 2022 ...

Page 86: ...o the eyes near the top of the underlift FIGURE 30 ATTACHING THE CABLES TO THE EYES EXAMPLE 5 With the winches set to free spool lift and extend the boom over the underlift Position the boom so that there is enough clearance to fully lift the underlift and the wire ropes run straight up and down from the hook points 6 Engage the winches and start lifting the underlift Continue lifting until you st...

Page 87: ...ndicated by arrows in the figure below To prevent the underlift from swinging when it is lifted out of the rails find its centre of gravity If the underlift swings too much it could hit the vehicle Never allow anyone near the wrecker when removing the underlift The underlift may swing and hit someone when it is removed resulting in serious injury or death FIGURE 31 POSITIONING THE UNDERLIFT IN THE...

Page 88: ... vertical position when it is not supported by the cables attached to the boom An underlift is heavy and may fall Always lay it flat on the ground FIGURE 32 PLACING THE UNDERLIFT ON A FLAT SURFACE EXAMPLE 10 Disconnect the two winch cables The boom is now ready for use 3 8 6 Removing the tag axle from the wrecker You can remove the tag axle from the wrecker in two ways l Remove the tag axle and th...

Page 89: ...e 1 Stop the hydraulic pumps by turning off the truck engine or disengaging the PTO 2 Ensure that the underlift is resting on its storage pin 3 Secure the underlift to the tag axle with its two locking pins FIGURE 33 SECURING THE UNDERLIFT TO THE TAG AXLE 89 Sliding Rotator Wreckers Operation and Maintenance Models CSR50 CSR65 CSR85 REV 0 SEPTEMBER 19 2022 ...

Page 90: ...LES AND HOSES IN THE DOCKING BRACKET EXAMPLE 5 Restart the engine or engage the PTO 6 Slightly raise the boom to relieve the pressure on the pins securing the tag axle assembly to the wrecker tag axle rails Remove the pins and store them 7 Slightly extend or retract the boom so the tag axle s centre of gravity allows the tag axle to slide freely in the rails Using the boom lift the tag axle close ...

Page 91: ...ing the underlift from the wrecker but instead of disconnecting the underlift s MultiFaster hydraulic coupler from the body disconnect it from the tag axle 2 Disconnect the MultiFaster hydraulic coupler that connects the tag axle to the body and place it in the docking bracket on the side of the tag axle 3 Restart the engine or engage the PTO 4 Lift and align the boom so that there are a few feet ...

Page 92: ... When the underlift has been removed you must put it back on the wrecker before leaving the site 1 Position the boom and the winch cable hooks so that you can attach the winch cable to the underlift 2 Connect the two winch cables to the eyes near the top of the horizontal part of the underlift stinger 3 Wind in the winch cables and if needed extend the boom to lift the underlift 4 Raise the boom s...

Page 93: ...inciples and follow the safety guidelines see Section 3 3 Safety guidelines Perform all the preliminary steps to ensure that the wrecker is stable and level see Sections 3 4 Familiarizing yourself with the equipment 3 7 1 Stabilizing the wrecker using the outriggers and 3 7 2 Levelling the wrecker 3 9 1 Preparing the slider and rotator To allow the boom to move you first need to unlock the slider ...

Page 94: ... boom in either direction NOTE You can increase the boom rotation speed by activating the high speed function on the touchscreen interface This function also controls the winding and unwinding speed for the two main winch cables Adjust the speed control function to operate at low speed when working under load The boom can rotate continuously over the cab When the boom approaches the cab an electro...

Page 95: ...the way forward 3 On the touchscreen interface check that the boom is centred 4 Use the touchscreen interface to lock the boom rotation and check that it is locked Push the rotation lever up and down to ensure that the locks are activated the boom does not rotate and the boom is securely in its storage position 5 Use the touchscreen interface to lock the slide and check that it is locked Push the ...

Page 96: ...he boom make sure the winch cables or synthetic ropes can move freely or are disengaged Do not extend the boom if the hook is attached to the wrecker body This could damage the cables winches and sheave heads and cause injury or even death IMPORTANT This section provides general information on how to use the winches NRC equipment uses winches of various brands and models Always refer to the winch ...

Page 97: ...e cable You can increase the winding and unwinding speed of the main winch cable by activating the high speed function on the touchscreen interface This function also controls the boom rotation speed Adjust the speed control function to operate at low speed when working under load For safer operation it is recommended to never leave the equipment on the high speed option Always put it back on low ...

Page 98: ...ker with the remote control is selected the truck will turn off 3 On the touchscreen interface select the option to control the wrecker with the remote control 3 11 2 Operating the wrecker with the remote control To operate the wrecker using the remote control l To turn the wrecker engine on or off use the appropriate switch on the remote control see Table 2 l To disengage a winch push and hold th...

Page 99: ...t can be used to perform many actions such as viewing the hours of operation calibrating the system viewing the system information modules and logs and setting your preferences Your wrecker is equipped with the MD4 7 model See the manual for your touchscreen model 99 Sliding Rotator Wreckers Operation and Maintenance Models CSR50 CSR65 CSR85 REV 0 SEPTEMBER 19 2022 ...

Page 100: ...Operation and Maintenance 100 Sliding Rotator Wreckers Operation and Maintenance Models CSR50 CSR65 CSR85 REV 0 SEPTEMBER 19 2022 ...

Page 101: ...er underlift boom or winches always l Ensure that you fully understand all the safety rules described in Chapter 2 Safety l Wear protective clothing goggles gloves footwear etc l Watch out for moving parts l Watch out for hot components l When working under the vehicle apply the parking brake and use wheel chocks l When lifting the vehicle use approved and certified equipment that is in good condi...

Page 102: ...sure See Section 4 4 1 Adjusting the hydraulic pressure main relief X Check the cable tensioner for all winches See Section 4 2 4 Winch cable tensioner Check the dial on the right side of the wrecker The dial should indicate a pressure of approximately 75 to 90 psi 5 2 to 6 2 bar to maintain the correct cable pressure X Inspect the bolts on the chassis mounting plates for damage and make sure they...

Page 103: ... pins on the MultiFaster X Visually inspect the cable s to ensure that they are in good condition lubricated and properly wound See Section 4 2 5 Steel cable maintenance X Check that no cylinders or hoses are leaking X Inspect all anchors eyes and pulleys for cracks and structural damage X Check the condition of the high pressure oil filter and that all the high pressure indicators are green If th...

Page 104: ... that they are in good condition If they are in poor condition replace them See Section 4 2 6 Wear pads maintenance X Clean and lubricate the lever arms on the main control valve Remove the cover from the manual override control panel to access the main control valve X Clean the levers on the manual override control panel X Have an NRC authorized distributor check the hydraulic system See Section ...

Page 105: ...imately 80 psi Adjust the pneumatic pressure using the integrated regulator when necessary 4 2 5 Steel cable maintenance Steel cables must be regularly inspected to ensure safe operation When a cable is degraded deformed or bent you must replace it See the ISO 4309 2017 standard for the criteria for inspection maintenance and disposal of steel cables The cable dimensions vary based on the winch mo...

Page 106: ... 40000 winch CSR50 Main 200 19 mm 3 4 6X36 WS EIPS1960 IWRC Steel cable for the Ramsey RPH 15000 winch CSR50 Auxiliary 200 14 mm 9 16 6X36 WS EIPS1960 IWRC Steel cable for the DP 20000 winch CSR50 and CSR65 Auxiliary 200 16 mm 5 8 6X36 WS EIPS1960 IWRC Steel cable for the DP 50000 winch CSR65 Main or drag 200 22 mm 7 8 6x36 WS EIPS1960 IWRC Steel cable for the DP 60000 winch CSR85 Main 200 22 mm 7...

Page 107: ... must be replaced according to the replacement frequency and other information shown in Table 16 Make sure to recycle or dispose of the worn wear pads in accordance with local legislation 107 Sliding Rotator Wreckers Operation and Maintenance Models CSR50 CSR65 CSR85 REV 0 SEPTEMBER 19 2022 ...

Page 108: ... On the tube of the different sections See Figure 36 Boom wear pads 6 When the thickness of the nylatron reaches the fixing bolt or anchor On the tube of the different sections See Figure 37 Outrigger wear pads Front outriggers 16 Rear outriggers 16 When the thickness of the nylatron reaches the fixing bolt or anchor On the tube of the different sections See Figure 38 and Section 4 4 7 Disassembli...

Page 109: ...Operation and Maintenance FIGURE 36 WEAR PADS UNDERLIFT FIGURE 37 WEAR PADS BOOM 109 Sliding Rotator Wreckers Operation and Maintenance Models CSR50 CSR65 CSR85 REV 0 SEPTEMBER 19 2022 ...

Page 110: ...Operation and Maintenance 110 Sliding Rotator Wreckers Operation and Maintenance Models CSR50 CSR65 CSR85 REV 0 SEPTEMBER 19 2022 FIGURE 38 WEAR PADS OUTRIGGERS FIGURE 39 WEAR PADS SLIDERS ...

Page 111: ...for recycling NOTE Oil types for other equipment included with NRC equipment e g winch are provided for reference only See the manufacturer s manual e g winch manufacturer s manual for the appropriate oil type and frequency for your application and model TABLE 17 OIL TYPES AND LOCATIONS Description Quantity Oil Type or Commercial Name Frequency Location Hydraulic oil Fill up to 3 in from the top o...

Page 112: ... 50000 and DP 60000 winches Fill to the level indicated on the winch 80W90 or 85W140 depending on the operating temperature See the winch manufacturer s manual After the first 10 hours of operation Then annually or at every 250 hours of operation Winch oil tank See Section 4 2 5 Steel cable maintenance for the location of the winch Oil for the winch cables Along the full length of the cables as re...

Page 113: ...Operation and Maintenance FIGURE 40 OIL TANK CSR50 AND CSR65 FIGURE 41 SWING DRIVE LOCATION 113 Sliding Rotator Wreckers Operation and Maintenance Models CSR50 CSR65 CSR85 REV 0 SEPTEMBER 19 2022 ...

Page 114: ...l and locations depend on the wrecker model Contact your NRC distributor for the cartridge model number that applies to your wrecker model TABLE 18 FILTERS FOR THE CSR50 Description Quantity Commercial Name Replacement Frequency Location High pressure filter 2 Hydac high pressure filter with visual indicator Every year To access the high pressure filter move the boom back See Figure 42 Return filt...

Page 115: ...re filter with visual indicator Every year The high pressure filters are located inside the tunnel toolbox Open the small doors in the toolbox to access the filters See Figure 44 Return filter 1 MP Filtri MPF return filter After the first 6 months Then every year On the oil tank See Figure 44 115 Sliding Rotator Wreckers Operation and Maintenance Models CSR50 CSR65 CSR85 REV 0 SEPTEMBER 19 2022 ...

Page 116: ...Operation and Maintenance 116 Sliding Rotator Wreckers Operation and Maintenance Models CSR50 CSR65 CSR85 REV 0 SEPTEMBER 19 2022 FIGURE 44 FILTERS CSR65 ...

Page 117: ...e if your wrecker has 4 outriggers make sure to grease all grease fittings even if the outrigger shown below is for the left outrigger TABLE 20 GREASE SCHEDULE Description Lubricant Type After Every 6 mths 1 mth 3 mths 1 yr Underlift surfaces and grease fittings Waterproof grease X Outrigger surface Waterproof grease X Boom and winches Waterproof grease X X Mast surfaces Waterproof grease X All va...

Page 118: ...int Grease fitting 3 Sliding surfaces of each extension Note 1 Grease fitting 4 Fold pivot Grease fitting 5 Extension cylinder anchor point Grease fitting 6 Underlift roller Grease fitting 7 Fold cylinder anchor point Grease fitting 8 Fold cylinder anchor point Note 2 Grease fitting Note 1 Fully extend the underlift to access all grease fittings Note 2 Completely fold the underlift to access the g...

Page 119: ...on the front and rear outriggers Lubrication point Type 1 Extension cylinder anchor point Grease fitting 2 Sliding surfaces of each extension Note 1 Surface 3 D ring Grease fitting 4 Recovery spade Grease fitting 5 Recovery spade plunger lock Grease fitting 6 Outrigger leg anchor point Grease fitting 7 Outrigger up down cylinder anchor point Grease fitting 119 Sliding Rotator Wreckers Operation an...

Page 120: ...urface top sides bottom of every extension Move the outriggers in and out several times to spread the grease evenly on all surfaces Regularly and thoroughly grease the outriggers so their surfaces are always lubricated and protected against corrosion TABLE 23 LUBRICATION POINTS OUTRIGGERS TOP ANCHOR POINTS Lubrication point Type 1 Outrigger up down cylinder anchor Grease fitting ...

Page 121: ...CHES NOTE See the manufacturer s manual for the appropriate grease type and frequency for your application and model TABLE 26 LUBRICATION POINTS BOOM EXTENSION CYLINDERS NOTE The number of grease fittings may vary depending on your boom model 121 Sliding Rotator Wreckers Operation and Maintenance Models CSR50 CSR65 CSR85 REV 0 SEPTEMBER 19 2022 ...

Page 122: ...R50 CSR65 CSR85 REV 0 SEPTEMBER 19 2022 Lubrication point Type 1 Boom extension cylinder anchor point 2 per extension Note 1 Grease fitting Note 1 Extend the boom to access the fittings TABLE 27 LUBRICATION POINTS BOOM NOTE The number of grease fittings may vary depending on your boom model ...

Page 123: ...ey bushing Grease fitting 2 Underlift locking system Grease fitting 3 Main winch rotation Grease fitting 4 D ring Grease fitting 5 D ring Grease fitting 123 Sliding Rotator Wreckers Operation and Maintenance Models CSR50 CSR65 CSR85 REV 0 SEPTEMBER 19 2022 ...

Page 124: ...EV 0 SEPTEMBER 19 2022 Lubrication point Type 6 D ring Grease fitting TABLE 28 LUBRICATION POINTS BOOM AND SLIDER BASE NOTE The number of grease fittings may vary depending on your wrecker model Lubrication point Type 1 Rotation axis of the boom Grease fitting 2 Lift cylinder anchor point top Grease fitting ...

Page 125: ...chor point Grease fitting 8 Slider bottom pad Grease fitting 9 Slider top pad Grease fitting 10 Lift cylinder anchor point bottom Grease fitting 11 Slider top pad Grease fitting TABLE 29 LUBRICATION POINTS SLIDER BASE NOTE The number of grease fittings may vary depending on your wrecker model 125 Sliding Rotator Wreckers Operation and Maintenance Models CSR50 CSR65 CSR85 REV 0 SEPTEMBER 19 2022 ...

Page 126: ...nance 126 Sliding Rotator Wreckers Operation and Maintenance Models CSR50 CSR65 CSR85 REV 0 SEPTEMBER 19 2022 Lubrication point Type 1 Boom extension cylinder anchor point Grease fitting 2 Slider bottom pad Grease fitting ...

Page 127: ...ast pressure For each hydraulic system the pressure must be adjusted to 3 000 psi 207 bar for the CSR50 and 3 500 psi 241 bar for the CSR65 To adjust the pressure of each hydraulic system you will first need to increase the pressure of each valve to 3 100 psi for the CSR50 or 3 600 psi for the CSR65 If you cannot reach this value by increasing the pressure of the valves the pump pressure is too lo...

Page 128: ...There are two valves for each hydraulic system one in the boom base behind the steel cover and one inside the wrecker body under the wrecker floor FIGURE 46 POSITION OF THE VALVES IN THE BOOM BASE CSR50 AND CSR65 FIGURE 47 POSITION OF THE VALVES INSIDE THE WRECKER BODY CSR50 AND CSR65 To check the hydraulic pressure of each system ...

Page 129: ...re reads 3 000 psi for the CSR50 or 3 500 psi for the CSR65 NOTE The pumps are located underneath the truck near the transmission If the pressure is not at the appropriate setting indicated above for a hydraulic system you need to adjust the pressure of both valves in the system as follows Do not turn the adjusting screw of the hydraulic valve while operating a hydraulic control as this may perman...

Page 130: ...ve two turns to increase the pressure b Re test the hydraulic pressure as described in step 3 above and check that it reads approximately 3 100 psi for the CSR50 or 3 600 psi for the CSR65 If you cannot reach this value by adjusting the valves the pump pressure is not high enough In that case you need to increase the pump pressure to 3 100 psi for the CSR50 or 3 600 psi for the CSR65 before procee...

Page 131: ...ctly the correct value d Tighten both locknuts For the CSR85 The CSR85 has one hydraulic system which is composed of one hydraulic pump and three hydraulic valves To adjust the pressure of the hydraulic system you first need to adjust the pressure of the pump to 3 970 psi 274 bar If you cannot reach 3 970 psi the valves are not adjusted properly and you should increase their pressure one by one un...

Page 132: ...32 Sliding Rotator Wreckers Operation and Maintenance Models CSR50 CSR65 CSR85 REV 0 SEPTEMBER 19 2022 FIGURE 49 POSITION OF THE HYDRAULIC PUMP PRESSURE ADJUSTING SCREW CSR85 FIGURE 50 POSITION OF THE VALVE IN THE BOOM BASE CSR85 ...

Page 133: ...ing 2 Engage the PTO 3 Operate the lever that moves the right outrigger up when the outrigger is already all the way up Check that the pump pressure reads 3 970 psi on the touchscreen interface and that the x port pressure is 3 770 psi NOTE The pumps are located underneath the truck near the transmission Then adjust the pressure of the three valves as follows 133 Sliding Rotator Wreckers Operation...

Page 134: ...t on each valve and screw the adjusting screw two turns to increase the pressure b Re test the hydraulic pressure as described in step 3 above and check that it reads above 3 970 psi If you cannot reach 3 970 psi by adjusting the valves the pump pressure is not high enough In that case you need to increase the pump pressure to 3 970 psi before proceeding with adjusting the valves To do so screw th...

Page 135: ...2 Adjusting the counterbalance valves CBCG LJN The wrecker has ten counterbalance valves which are all adjusted with the same adjustment Completely screw and then unscrew 3 turns l Two are used to control the pressure of the boom in out cylinder They are located inside the boom l Two are used to control the pressure of each outrigger s up down cylinder They are located above each outrigger up down...

Page 136: ...n the set screw counter clockwise to the appropriate setting described above and keep the screw in this position while you tighten the jam nut NOTE Position the Allen key so you can easily count how many turns you make when setting the screw 4 4 3 Adjusting the sequence valve SCCA LAN The wrecker has one sequence valve which is located in the boom shown below This valve ensures that the larger sec...

Page 137: ...mpletely unscrew and then screw 3 turns Do not turn the adjusting screw of the hydraulic valve while operating a hydraulic control as this may permanently damage the valve 137 Sliding Rotator Wreckers Operation and Maintenance Models CSR50 CSR65 CSR85 REV 0 SEPTEMBER 19 2022 ...

Page 138: ...ropriate setting described above and keep the screw in this position while you tighten the jam nut NOTE Position the Allen key so you can easily count how many turns you make when setting the screw 4 4 4 Adjusting the rotation motor relief valves RV3A The wrecker has two relief valves for the rotation lock one for the clockwise rotation and another for the counterclockwise rotation These relief va...

Page 139: ... speed to between 600 and 850 rpm NOTE This is required to obtain an accurate pressure reading 2 Engage the PTO 3 Lock the boom rotation 4 Operate the rotation control Read the pressure on the touchscreen interface and check that it is at the appropriate setting specified above Release the hydraulic control 139 Sliding Rotator Wreckers Operation and Maintenance Models CSR50 CSR65 CSR85 REV 0 SEPTE...

Page 140: ...alve 4 4 5 Adjusting the underlift cushioning valve The underlift cushioning valve is located inside the top rear section of the frame under the aluminium cover Should you have problems folding or unfolding the underlift you may have to adjust the valve The B A cartridge controls the folding and the C D cartridge controls the unfolding Both cartridges need to be set to 2 000 psi 138 bar Ensure tha...

Page 141: ...ulic control as this may permanently damage the valve 6 Try folding up the underlift If it still lacks power repeat Step 5 until the underlift folds correctly Do not apply excessive pressure use the minimum required to fold it correctly 7 Tighten the locknut 4 4 6 Aligning the boom IMPORTANT Lock the sliding rotator before checking the boom alignment Check the boom alignment 141 Sliding Rotator Wr...

Page 142: ... indicator sensor is adjusted and is able to detect that the boom is centred visually verify again that the boom is centred 3 If the boom is out of alignment align it as follows Align the boom by adjusting the screws on the front locks 1 Loosen the locknuts securing the adjustment bolts 2 Screw the bolts in or out Tighten the locknuts 4 4 7 Disassembling the outriggers For the CSR50 Disassembly 1 ...

Page 143: ...s 6 While still supporting the small section completely remove it from the middle section You may have to jiggle the small section to remove it Carefully place the small section on the ground 7 Support the middle section with an appropriate tool Repeat the previous steps to remove the middle section from the large section Carefully place the middle section on the ground 8 Replace all the nylon pad...

Page 144: ...BER 19 2022 FIGURE 59 DISASSEMBLING THE OUTRIGGER CSR50 Reassembly To reassemble the outrigger reverse the disassembly procedure For the CSR65 and CSR85 Disassembly 1 Extend the outrigger and stop when the small section 1 is extended approximately 10 15 inches so you can access the steel shims 3 of the middle section 2 ...

Page 145: ...ylinder remove the cylinder with the small section Carefully place the cylinder and small section on the ground Make sure to properly support the small section during disassembly It is heavy and may cause damage or injury if it is unsupported and falls to the ground Support the outrigger according to the centre of gravity which will move while you remove the small section 7 Support the middle sect...

Page 146: ...nce 146 Sliding Rotator Wreckers Operation and Maintenance Models CSR50 CSR65 CSR85 REV 0 SEPTEMBER 19 2022 FIGURE 60 DISASSEMBLING THE OUTRIGGER CSR85 Reassembly To reassemble the outrigger reverse the disassembly procedure ...

Page 147: ...ems their main causes and solutions The following sections provide detailed procedures for some of the solutions NOTE Only distributors are authorized to perform repairs that involve replacing parts 147 Sliding Rotator Wreckers Operation and Maintenance Models CSR50 CSR65 CSR85 REV 0 SEPTEMBER 19 2022 ...

Page 148: ...lutions The levers on the left hand side control panel don t work The remote control switch is in the remote control position Set the remote control switch to the control panel not remote control position The PTO is not engaged Engage the PTO The control panel has no power Check the DC power 12 VDC in North America and 24 VDC elsewhere on the main electrical panel main relay and check the control ...

Page 149: ...s centred The sensor is not detecting the position of the boom Move the boom all the way to the front of the wrecker to ensure that it can be detected by the sensor The boom position sensor is faulty or absent Replace the sensor It is located in the centre left right of the wrecker on the structure retaining the rotation lock To access it move the sliding rotator to the rear of the wrecker The win...

Page 150: ...noid is burned out Replace the main solenoid in the main electrical panel The sliding rotator lacks power when rotating The rotation valves are not adjusted properly Adjust the rotation relief valves see Section 4 4 4 Adjusting the rotation motor relief valves RV3A The sliding rotator won t unlock The solenoid air pressure is too low Check for an air leak or a bent hose The solenoid wiring is dama...

Page 151: ...freely Remove the obstruction The wear pads are not in place or sufficiently lubricated Ensure that all wear pads are in place and well lubricated One or more underlift sections are bent Use a straight edge to see whether all the underlift sections are straight If one is bent have it repaired You can also remove the steel spacers one by one and see whether that makes a difference The IN OUT cylind...

Page 152: ...he holding valves are not adjusted properly Adjust the holding valves Rubber or silicone particles in the hydraulic fluid are stuck in the holding valves or cartridges Fully lower the boom Loosen the nut that locks the set screw on the cartridge Turn the set screw clockwise until it stops This opens the valve completely Fully retract and extend the boom several times This flushes the cartridge and...

Page 153: ...ance valves CBCG LJN The boom cylinder is faulty Check the boom cylinder and have it repaired or rebuilt see Section 5 2 Checking the boom cylinder The levelling system does not level the wrecker correctly The outriggers do not touch the ground Ensure that ONLY the outrigger feet touch the ground The levelling system is not calibrated For wreckers with a display recalibrate the levelling system in...

Page 154: ...l should leak unless there is a broken piston damaged seal or broken cartridge NOTE You will need a load e g another vehicle for this procedure 1 Lower the underlift completely 2 Choose a lifting point on the vehicle to be towed It must be both strong enough and have enough clearance for the underlift to move Using a poor lifting point may damage the towed vehicle and wrecker or even cause a serio...

Page 155: ...c system 9 Disengage the winch that is keeping the boom retracted If the boom does not stay retracted the cylinder has to be rebuilt or replaced 155 Sliding Rotator Wreckers Operation and Maintenance Models CSR50 CSR65 CSR85 REV 0 SEPTEMBER 19 2022 ...

Page 156: ...Operation and Maintenance 156 Sliding Rotator Wreckers Operation and Maintenance Models CSR50 CSR65 CSR85 REV 0 SEPTEMBER 19 2022 ...

Page 157: ...failure must be repaired before performing other towing operations Contact your distributor to correct the problem 6 2 Hydraulic failure In the event of a hydraulic failure the hydraulic pressures required for normal operation are not reached in the circuits The hydraulic pump or PTO may be the cause The hydraulic failure must be repaired before performing other towing operations To troubleshoot a...

Page 158: ...boom outriggers etc are in their stored position i e the position for travel without a load bring your equipment to a repair location If some components are not in their stored position and it is not possible to safely get to a repair point the pump must be repaired or replaced on site 6 4 Truck failure In the event of a vehicle breakdown you will not be able to operate the equipment Have the equi...

Page 159: ... 3 Position the parts so that the cylinders are fully retracted 4 Lubricate any exposed cylinder rods 5 Disconnect the electrical power supply to avoid depleting the batteries When taking your wrecker out of storage 1 Clean and lubricate all parts including the slider 2 Replace the high pressure and return filters on the hydraulic reservoir 3 Check the oil level and pressure 4 Connect the electric...

Page 160: ...Operation and Maintenance 160 Sliding Rotator Wreckers Operation and Maintenance Models CSR50 CSR65 CSR85 REV 0 SEPTEMBER 19 2022 ...

Page 161: ...ply with all effective regulations including the RoHS Directive for electrical components when disassembling the machine and disposing of the following parts l Electrical components l Rubber hydraulic hoses l Painted parts l Metal l Composite materials To protect both you and the environment we recommend having a specialized company disassemble your machine 161 Sliding Rotator Wreckers Operation a...

Page 162: ...Operation and Maintenance 162 Sliding Rotator Wreckers Operation and Maintenance Models CSR50 CSR65 CSR85 REV 0 SEPTEMBER 19 2022 ...

Page 163: ...towing requirements This section presents the most common types of accessories available Contact your NRC distributors to learn more about the full range of accessories available for your wrecker model 163 Sliding Rotator Wreckers Operation and Maintenance Models CSR50 CSR65 CSR85 REV 0 SEPTEMBER 19 2022 ...

Page 164: ...onents used with fork holders They are installed on the T head of the T bar and can be used to hold the vehicle towed by the chassis axles or structural members FIGURE 61 EXAMPLE OF FORKS FIGURE 62 EXAMPLE OF FORK HOLDERS 9 1 1 How to use forks and fork holders Install the fork holders on the T head of the T bar There are several positions in which they can be installed ...

Page 165: ...r pin provided 3 Install the fork in the fork holder Once in place position the axle or chassis or other structural members of the towed vehicle on the forks then secure the vehicle in place FIGURE 63 INSTALLING THE FORKS AND FORK HOLDERS 165 Sliding Rotator Wreckers Operation and Maintenance Models CSR50 CSR65 CSR85 REV 0 SEPTEMBER 19 2022 ...

Page 166: ...and the T bar They can be used in place of the fork holders and forks FIGURE 64 EXAMPLE OF HOLDERS WITH INTEGRATED FORKS 9 2 1 How to use holders with integrated forks Install the holders with integrated forks on the T head of the T bar There are several positions in which they can be installed 1 Position the holders with integrated forks on the T head of the T bar 2 Secure them in place using the...

Page 167: ...Operation and Maintenance FIGURE 65 EXAMPLE OF HOLDERS WITH INTEGRATED FORKS 167 Sliding Rotator Wreckers Operation and Maintenance Models CSR50 CSR65 CSR85 REV 0 SEPTEMBER 19 2022 ...

Page 168: ...EXAMPLE OF TOW BAR BRACKETS 9 3 1 How to use tow bar brackets Install the tow bar brackets on the T head of the T bar There are several positions in which they can be installed to adapt to the towed vehicle 1 Position the tow bar brackets on the T head of the T bar 2 Secure them in place using the locking pin Once they are in place position the axle or chassis or other structural members of the to...

Page 169: ...Operation and Maintenance FIGURE 67 INSTALLING THE TOW BAR BRACKETS 169 Sliding Rotator Wreckers Operation and Maintenance Models CSR50 CSR65 CSR85 REV 0 SEPTEMBER 19 2022 ...

Page 170: ...nt widths The positions of the angled plates can also be adjusted to fit different wheel sizes FIGURE 68 EXAMPLE OF HEAVY DUTY TIRE LIFTS 9 4 1 How to use heavy duty tire lifts The heavy duty tire lifts fit directly on the T head of the T bar and are secured in place with a locking pin 1 Position the heavy duty tire lifts at the appropriate position on the T head of the T bar Make sure to position...

Page 171: ... wheels of the vehicle on the angled plates 2 Use straps to secure the vehicle in place These go around the tire and attach to the back of the tire lifts FIGURE 69 INSTALLING THE HEAVY DUTY TITRE LIFTS ON THE T HEAD FIGURE 70 INSTALLING THE STRAPS 171 Sliding Rotator Wreckers Operation and Maintenance Models CSR50 CSR65 CSR85 REV 0 SEPTEMBER 19 2022 ...

Page 172: ... and secured in place with locking pins They can be installed at different positions on the T head to fit vehicles of different widths The positions of the angled plates can also be adjusted to fit different wheel sizes FIGURE 71 EXAMPLE OF MEDIUM DUTY TIRE LIFTS 9 5 1 How to use the medium duty tire lifts The medium duty tire lifts fit directly on the T head of the T bar and are secured in place ...

Page 173: ...s are installed load the vehicle on the brackets and secure the vehicle in place 1 Position the wheels of the vehicle on the angled plates 2 Use straps to secure the vehicle in place These go around the tire and attach to the back of the tire lifts FIGURE 72 INSTALLING THE MEDIUM DUTY TIRE LIFTS 173 Sliding Rotator Wreckers Operation and Maintenance Models CSR50 CSR65 CSR85 REV 0 SEPTEMBER 19 2022...

Page 174: ... vehicle to the spreader bar Once the vehicle is secure you can proceed with recovery operations Ensure that you do not exceed the capacities indicated on the spreader bar to ensure safe recovery and prevent dangerous situations Spreader bars have the following capacities TABLE 31 SPREADER BAR CAPACITIES 3 SECTION SHORT IN METRIC IMPERIAL Element Specification 30 Retracted 6 000 kg 13 000 lb Exten...

Page 175: ...Operation and Maintenance FIGURE 73 EXAMPLE OF A SPREADER BAR 175 Sliding Rotator Wreckers Operation and Maintenance Models CSR50 CSR65 CSR85 REV 0 SEPTEMBER 19 2022 ...

Page 176: ...MBER 19 2022 9 7 Snatch block Snatch blocks are accessories used during vehicle recovery operations They allow different setups to facilitate recovery Ensure that you do not exceed the capacities indicated on the snatch block to ensure safe recovery and prevent dangerous situations FIGURE 74 EXAMPLE OF A SNATCH BLOCK ...

Page 177: ... EXAMPLE OF A DRAWBAR ADAPTER 9 8 1 How to use the drawbar adapter The drawbar adapter is installed on the ladder plates at the rear of the tow truck It is held in place with a locking pin 1 Position the drawbar adapter on the ladder plates 2 Secure it in place using the locking pin 177 Sliding Rotator Wreckers Operation and Maintenance Models CSR50 CSR65 CSR85 REV 0 SEPTEMBER 19 2022 ...

Page 178: ...Operation and Maintenance 178 Sliding Rotator Wreckers Operation and Maintenance Models CSR50 CSR65 CSR85 REV 0 SEPTEMBER 19 2022 FIGURE 76 INSTALLING THE DRAWBAR ADAPTER ...

Page 179: ...lways be installed when using the outriggers FIGURE 77 EXAMPLE OF A WOOD PAD 9 9 1 How to use the wood pads The wood pads are installed on the outriggers and are held in place with a locking pin 1 Position one wood pad on each outrigger 2 Secure each wood pad in place using the locking pin 179 Sliding Rotator Wreckers Operation and Maintenance Models CSR50 CSR65 CSR85 REV 0 SEPTEMBER 19 2022 ...

Page 180: ...Operation and Maintenance 180 Sliding Rotator Wreckers Operation and Maintenance Models CSR50 CSR65 CSR85 REV 0 SEPTEMBER 19 2022 FIGURE 78 INSTALLING THE WOOD PADS ...

Page 181: ...p and prevent the tow truck from sliding FIGURE 79 EXAMPLES OF STABILIZER GRIPS 9 10 1 How to use stabilizer grips The stabilizer grips that attach to the wood pads fit directly onto them Contact with the ground keeps the stabilizer grips in place 1 Position one stabilizer grip on the wood pad on each outrigger 2 Lower the outrigger to make contact with the ground 181 Sliding Rotator Wreckers Oper...

Page 182: ...R 19 2022 FIGURE 80 INSTALLING A STABILIZER GRIP ON A WOOD PAD The stabilizer grips that fit directly on the outriggers are held in place with a locking pin 1 Position one stabilizer grip on each outrigger 2 Secure each stabilizer grip in place using the locking pin FIGURE 81 INSTALLING A STABILIZER GRIP ON AN OUTRIGGER ...

Page 183: ... the chain boxes on the tow truck as well as on the towed vehicle Tow chains are attached to the towed vehicle as well as to the underlift or T bar The use of safety and tow chains may be governed by law Make sure to always follow applicable regulations NRC also offers chains with a closed hook They are used to perform different lifting operations 183 Sliding Rotator Wreckers Operation and Mainten...

Page 184: ...Operation and Maintenance 184 Sliding Rotator Wreckers Operation and Maintenance Models CSR50 CSR65 CSR85 REV 0 SEPTEMBER 19 2022 ...

Page 185: ... PROVIDERS Please visit our website for the list of authorized distributors and service providers or scan the QR code below https nrc industries com nrc dealer 185 Sliding Rotator Wreckers Operation and Maintenance Models CSR50 CSR65 CSR85 REV 0 SEPTEMBER 19 2022 ...

Page 186: ...Operation and Maintenance 186 Sliding Rotator Wreckers Operation and Maintenance Models CSR50 CSR65 CSR85 REV 0 SEPTEMBER 19 2022 ...

Page 187: ...lowing information Logbook Date Routine Maintenance Frequenc y Flushing Greasing Tightening Other Tasks Inspections Disassembly Repairs Name and Title Number of Hours of Operation Observations Part Numbers 187 Sliding Rotator Wreckers Operation and Maintenance Models CSR50 CSR65 CSR85 REV 0 SEPTEMBER 19 2022 ...

Page 188: ...Operation and Maintenance 188 Sliding Rotator Wreckers Operation and Maintenance Models CSR50 CSR65 CSR85 REV 0 SEPTEMBER 19 2022 ...

Page 189: ...Operation and Maintenance OPERATOR RECORD Operator Name Date 189 Sliding Rotator Wreckers Operation and Maintenance Models CSR50 CSR65 CSR85 REV 0 SEPTEMBER 19 2022 ...

Page 190: ...2430 Principale St Paul d Abbotsford QC J0E 1A0 T 450 379 5796 F 450 379 5796 NRC INDUSTRIES COM ...

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